Blank for and method of making axle housings



Feb. 2, 1937. E. RIEMEN SCHNEIDER Eli/u. 2,069,480

BLANK FOR AND METHOD OF MAKING AXLE HOUSINGS Jiled June 7, 1952 2Sheets-Sheet l INVENTORS fire/780617210 0- 577ml Pie 1 14/4020: 30:1JmzZ/z W Z ZATTORNEY 1937. E. RIEMENSCHNEIDER ET AL 2,069,480

BLANK FOR AND METHOD OF MAKING AXLE HOUSINGS Filed June 7, 1932 2Sheets-Sheet 2 Patented Feb. 2, 1937 UNITED STATES PATENT ()FFlCE BLANKFOR AND METHOD OF MAKING AXLE HOUSINGS corporation of Ohio ApplicationJune 7, 1932, Serial No. 615,848

19 Claims.

This invention relates to new and useful improvements in tubulararticles, more particularly to the axle housing type and relates to theblank and method of forming the same into sections 5 for the formationof complete axle housings.

An important object of the invention is to provide a method ofmanufacturing axle housings from a minimum amount of material fromeither flat or tubular stock and is made possible by 1 operating uponthe stock from one end rather than its mid-section, whereby said end canbe spread or expanded with the simplest equipment to become appropriatesize and shape for the gear housing portion and at the same time pro- 15vide an opening without scrap losses for the admission of thedifferential gearing.

Another important object of the invention is to provide a tubularsection tapering into an enlarged end, oval in cross section, andproviding 20 said enlarged end with slots arranged relative thereto andthe tapered portion of the section so that in subsequent forming, theslots will define the approximate edges of the arms and control theirsymmetrical disposition while they are 25 being bent toward their finalarcuate shape.

A further object of the invention is to provide a blank which can beformed into a tube of circular section at one end and an enlargeddeveloped end of oval section at the other with a 30 connecting taperedportion which cooperates in controlling subsequent bending withoutreceiving adverse conditions and characteristics so as to retain itsrequisite cross section, substantial shape and wall thickness to providethe neces- 35 sary strength.

Another important object of the invention is to provide a welded tubularsection with provision for the lack of displacement or flow of metal inthe welded portion during subsequent forming 40 operations.

Another object of the invention is to provide a unit including backingplate and bearing ring flanges for attachment to the reduced ends of thehousing, the shoulders of both elements co- 0 operating in thede-marking points of attachment and lending themselves to rapid weldingtogether of the parts to be united.

Other objects and advantages of the invention 50 will become apparentduring the course of the following description.

In the accompanying drawings forming a part of the description andwherein like numerals are employed to designate like parts throughoutthe 55 several views,

Fig. 1 is a plan of a flat blank from which onehalf of the rear axlehousing is formed,

Fig. 2 is an end elevation of the same,

Fig. 3 is a plan of the same blank with its longitudinal edges flangedfrom the first forming operation,

Fig. 4 is an end elevation of the same,

Fig. 5 is a plan of the same blank formed into tubular sections,

Fig. 6 is an end elevation of the same,

Fig. 7 is a plan of the formed tube after being welded showing thediametrical disposition of the openings in the enlarged oval endthereof,

Fig. 8 is an end View of the same.

Fig. 9 is a view similar to Fig. '7 showing the tubular section dividedup to the slot or opening,

Fig. 10 is an end elevation of the same,

Fig. 11 is an elevation of the tube after the enlarged oval end has beenspread into Y-shape,

Fig. 12 is an end elevation of the same, 2

Fig. 13 is an elevation of the section after the forked arms have beenbent into arcuate shape,

Fig. 14 is an end elevation of the same,

Fig. 15 is a view showing the axle housing section after the trimmingoperation,

Fig. 16 is an end elevation of the same,

Fig. 17 is a plan view showing two of the axle housing sections unitedin longitudinal alignment to form a substantially integral housing,

Fig. 18 is a similar view illustrating the bearing ring retainer andbrake apron flange secured to each end thereof,

Fig. 19 is a longitudinal section of the combined bearing ring retainerand brake apron flange unit.

Fig. 20 is a similar view illustrating the same attached to one end ofthe axle housing,

Fig. 20a is a top plan of the housing section shown in Fig. 15,

Figs. 21 to 31 inclusive correspond to Figs. 7 to 18 inclusive butillustrating a bearing ring retainer and brake apron flange formedintegral from the metal at opposite ends of the housing.

Fig. 32 is a longitudinal section of one end of the housing showing theone piece formation of the ring retainer and brake apron flange.

The manufacture of rear axle housings for motor vehicles has been acontinual problem to manufacturers from the standpoint of economizing inboth material and equipment. This has resulted in the practice of twodifierent methods of forming the housings, one of which proceeds fromflat blanking and the other from tubular stock. In the latter class,which effects a saving in scrap loss from blanking operations, specialequipment is necessary for operating upon the tubular section to form itinto a complete housing. The type of housing including a plurality oftubular sections with an independent gear housing portion, has not metwith favor due to the multiplicity of joints required, lack of strengthand being generally crude in appearance. The other specie of thistubular type patented by Mogan and others required expanding operationson the mid-section of the tube, necessitating elaborate and expensiveexpanding tools and resulting in an objectionable thinning of the wallsof the gear housing portion incident to the expanding operation.

The flat blank type of housing has always been objectionable by reasonof the excessive scrap loss of material in the blanking operation. Thistype generally includes the use of a blank having two pairs oftriangular wings adjacent its mid-section so common in the Murraypatents. The loss by scrap was attempted to be obviated in manydifferent ways, as for example by welding the triangular projections onthe edges of the flat blanks or by welding a plurality of blankstogether from which might be formed the tubular axle housing. Whileeffecting a saving in the amount of material employed, it necessitatedadditional welding and more joints in the axle housing than wassatisfactory.

The present invention proceeds from an economical blank because of itsability to be closely nested in the blanking operation which in turn ismade possible by the fact that the housing is constructed from a pair ofsimilar blanks giving rise to the possibility of forming the gearhousing portion at one end of the blank instead of upon its mid-sectionas exemplified in the older practice. By performing the spreading orexpanding operation on one end of the section, scrap losses are reduced,less expensive equipment is required for the spreading operation, andreduction of wall thickness of the gear housing portion is obviated.

Referring now more particularly in detail to the drawings, theinvention, although not necessarily, proceeds from a flat blank orblanks, there being two similar blanks employed for each axle housingand as both are identical in construction and formation, only one willbe described in detail. Reference has been made to the fact that theinvention preferably proceeds from flat blank stock and as will appearhereinafter, it is within the realm of this invention to begin withtubular stock.

The flat blank shown in Figs. 1 and 2. of the drawings is of sufficientlength to form one-half of the axle housing and is of a width sufficientto form up into a tubular section. This blank includes a pair ofsubstantially rectangular ends I and 2, the latter being considerablywider than the former, with an intermediate generally tapered portion 3.The longitudinal edges of this intermediate portion each possess threeportions which taper in varying degrees as indicated by the portions 4,5 and 6 to provide the finished half section with a gradually taperingportion connecting the tubular end of the axle housing section with theenlarged forked gear housing portion for the addition of strength. Thelongitudinal edges of the two substantially rectangular ends of theblanks are substantially parallel as illustrated and meet thelongitudinal edges of the tapered portion 3 as illustrated in Fig. l.

The transverse edge I of the wider end of the blank is developed toproperly meet conditions and characteristics of the stock and equipmentemployed in its formation, and in the present instance is provided witha pair of spaced notches 8 which define between them in a directionlongitudinally of the blank, a portion which subsequently forms up intosubstantially one-half of the tubular section. Between these twonotches, the enlarged end is developed into a longitudinally projectingextension 9 for the purpose of equaliz ing the length of the armsconstituting the forked gear housing portion during its subsequentformation. This developed extension 9 is desirable when certain types ofwelded stock are employed, but obviously may be eliminated or reduced indimensions when other types of stock are used. Its general purpose maytherefore be said to compensate for the greater displacement or flow ofmetal which occurs in the unwelded portions of the housing. In the bodyof the enlarged end of the blank, in longitudinal alignment with thenotches 8 are a pair of openings l0 which have their inner ends locatedapproximately in a plane at the juncture of the tapered portion with theenlarged end 2. Preferably, these openings are sector or pear-shaped,each with its longitudinal edges converging in a longitudinal directiontoward its respective notch 8. The larger ends of the openings arepreferably arcuate in contour for the purpose of preventing checking orcracking of the metal when the arms of the gear housing portion arespread apart as will be subsequently described. While these openings areillustrated as terminating short of their respective notches 8, it isobvious that they may extend all the way to meet the notches either inthe form of a slot or a mere slit but it is preferable that theyterminate short of the notches in the fiat blanks whereby the bending ofthe blank into tubular form will be better controlled. In fact, it isnot necessary that these openings H] be punched while the blank is inthe fiat as provisions for them may be made after the blank has beenformed into tubular section. By reason of the blanks having one endenlarged, rather than the mid-section as has been the practiceheretofore, it is possible that these blanks may be closely nested inthe blanking operation from sheet or plate, thereby resulting in asaving of material.

In order to bring the flat blanks into a tubular section, thelongitudinal margins l2 thereof, are flanged longitudinally to impart tothe blank substantially channel formation, as shown in Figs. 3 and 4.This channel shaped blank is then further formed along longitudinallines into sub- 'stantially tubular section with the longitudinal edgesl3 of the blanks in parallel substantially contiguous relationship asshown in Figs. 5 and 6 so that upon slight further formation of thesection, the longitudinal edges are brought into abutment or asubstantial abutment to be welded along a longitudinal line I4, which isdisposed normal to the plane of the openings H] which are now disposedat diametrically opposite points in the tubular section. Due to theconfiguration of the blanks and the forming operations, the smaller endI of the blank is brought to circular cross-section whereas the enlargedend I6 is developed into an enlarged end I6 substantially oval orelliptical in cross section. The intermediate portion l'l obviouslyassumes tubular formation flaring outwardly from the portion I5 into theenlarged oval end I6. According to this process, it may be begun fromthe fiat blank shown in Fig. 1 or the process may start with the tubularsection shown in Fig. '7, either perforated as at III or not.

With the product in the tubular form as shown at Fig. 7, the enlargedend I6 is slit or slotted at diametrically opposite points along a lineor lines extending from the notches 8 into the openings l0. When slit,these slits extend from the apex of the openings H) to the medialportions of the notches 8 but it is preferable to actually slot theenlarged end as shown in Fig. 9 with the longi tudinal edges of the sloteither parallel or preferably slightly converging toward the enlargedfree end of the tubular section whereby the arms l9 and 20 formed fromthe enlarged end by the slitting or slotting thereof are slightly widerat their outer free ends than at the portions adjacent the inner ends ofthe slots. This provides the free ends of the arms with suflicientmaterial to cause the flanges thereof to be of substantially uniformwidth throughout after the arms are spread apart and bent into arcuateformation. In Fig. 9 it will be noted that the arm 20 of the bifurcatedenlarged end is longer than its complementary arm l9 and is arranged inthe portion of the tube opposite the welded seam M. This elongation isof course due to the pro vision of the extension 9 in the blank. Itspurpose is to provide for equalization in the arm length during the timethe arms l9 and 2e are spread apart and bent into arcuate shape, thisequalization being due to the fact that the usual non-ductile form ofwelded seam does not permit as ready a flow or displacement of the metalas occurs in the portions which are not welded, namely the arm 28 duringthe spreading and forming operations. As a result, during theseoperations, the metal of the arm 29 is displaced inwardly toward thetape-red portion to impart additional strength thereto as the arms arebeing separated and bent into arcuate formation shown in Fig. 13.

The next step in the method consists of subjecting the tubular sectionshown in Fig. 9 to the action of dies as explained in theRiemenschneider co-pending application Serial No. 595,532, filedFebruary 27th, 1932, to spread the two arms I9 and 20 apart and to givethem preliminary channel-shaped cross section as indicated by thenumeral 2! of Fig. 12. It will be particularly noted that the arms areseparated to an extent causing them to assume substantially the sameinclination as the tapered portions ii and thereby form the product intosubstantially Y-shape. This is done for the purpose of preventing anymaterial displacement of metal in the two arms to obviate thinning ofwall thickness thereof when the arms are undergoing the final bendingand shaping operation to bring them to the form shown in Fig. 13, and isdue to the fact that the male die employed in the Riemenschneidercopending application for bringing the product to the shape shown inFig. 13, does not begin to engage the arms l9 and 28] until itpractically bottoms. This action rather defers the final arcuate shapingof the arms and minimizes any possibility of serious displacement of themetal as practically all of the arcuate formation is imparted to thearms in the final stages of movement of the male die. A slightstretching of the metal in the web portion 22 may occur during thespreading and bending operation but this does not affect the finalproduct inasmuch as the arcuate edges 23 of the flanges 24 aresubsequently trimmed off along the dotted line 25. Likewise, the ends ofthe two arms 19 and 2B are trimmed to remove any inequalities of lengthand to prepare the same for a butt-welding operation which unites thearms of one section to the arms of a similar section in longitudinalalignment as shown in Fig. 17. The forming operations may or may not beused in simultaneously making the arcuate arms of the gear housingportion slightly wider than the intermediate tapered portion I1, and inthe event of the widening of the armsbeing adopted, this provision willcause the wider arms to taper and merge as at 26 into the intermediateportions to reinforce the same. The merging of the tubular intermediateportion ll into the more or less flat arms creates slight archedportions 2? on the top and bottom of the housing to gradually merge intothe arms for further reinforcement thereof.

In order to provide the axle housing sections with means for locatingthe attachment of brake apron flange and bearing ring retainer units,the smaller tubular end [5 of each axle housing section at any desiredstage of the method, may have its tubular end 15 reduced in diameter asat 28 and provides the tubular end IS with internal and externalshoulders, the latter being indicated by the numeral 29, to which brakeapron flange to be presently described, is united.

After the formation of two sections such as shown in Fig. 15, they areplaced in longitudinal alignment shown in Fig. 17 with the sheared endsof arms l9 and 2B of complementary sections arranged in edge to edgeabutment and welded across the arms and flanges as indicated by thenumeral 29. This union is preferably made by butt-welding the edgestogether although other forms of attachment may be employed.

Upon union of the two axle housing sections, the unitary structure isplaced in a jig for the simultaneous location and tacking of a pair ofunits shown in Fig. 19 to the shouldered ends of the housing. Theseunits are combined brake apron flanges and bearing ring retainerscomprising a collar 30 having an annular outwardly extending flange 3|,to the inner curve of which is fastened as at 32, preferably by weldinga ring 33, the outer flange 34 of which constitutes the bearing ringretainer. The joint between the ring and collar forms an internalshoulder which is adapted to be secured to the external shoulder 29 ofthe reduced end of a housing. After the housing has been placed in arotatable jig with the two units 30, tacked or spot-welded on the endsof the housing at the shoulders 29, two circumferential welds are madesimultaneously, one between the shoulder 32 and the shoulder 29 at oneend of the housing, and the other between the end of the collar 36 andthe housing at point at the other end of the housing. The housing isthen turned end for end and welded in the above manner so that bothunits 30 are welded inside and outside to the ends of the housing.Instead of welding the collar units on the housing, they of course maybe riveted if desired or secured in their place with any other suitablemeans.

In the modification of invention shown in Figs. 21 to 32 inclusive, therear axle housing is formed, with the exception of the bearing ringretainer and brake apron flange, in exactly the same manner as describedhereinbefore and corresponding numerals have been employed to designatecorresponding parts in the two modifications. Instead of forming thebrake apron flange as a separate unit, it may be formed integrally oneach end of the housing at any stage in the method but preferably afterthe blank has been formed into tubular section as shown in Fig. '7. Thiscombined brake apron flange and bearing ring retainer is preferablyformed by first upsetting the tubular end l5 of each axle section toincrease its wall thickness, after which it is enlarged in diameter toform a bearing ring retaining shoulder 36 after which the outer end isturned into an outwardly extending annular flange 31 of considerablewall thickness.

From an inspection of Fig. '7 of the drawings, it will be apparent thatthe enlarged end l6 of the tubular section is approximately twice thediameter in one direction of that of the smaller tubular end l5 andtherefore possesses suflicient metal to be formed into the largestpossible size gear housing portion without danger of the wall thicknessof this portion being reduced in subsequent forming operations. It ispreferred to unite the two tubular sections together to form a completeaxle housing with the welded seam of each disposed to meet one anotherin longitudinal alignment, but if desired for any reason, it is possiblethat the sections may be reversed relative to each other so as todispose the welded seam of one on top of the housing and the welded seamof the other section at the bottom of the housing. It is also possiblethat it may be desired to expand the enlarged end to a larger diameterthan provided by the blank and this is permissible due to the fact thatthe section can be operated upon from one end.

It is to be understood that various changes in the sequence of steps ofthis method may be varied to meet different conditions or to form otherarticles, some steps of the method may be entirely eliminated or theconstruction of the blank may be altered without departing from thespirit of the invention or the scope of the appended claims.

We claim:

1. The method of forming axle housings consisting of providing a flatblank, forming the same into a tubular section having one end largerthan the other and of substantially oval cross section, bifurcating saidlarger end along its minor diameter to divide it into a pair ofchannel-shaped arms, spreading said arms apart and bending them toarcuate shape, and uniting a pair of such similar sections inlongitudinal alignment.

2. The method of forming axle housings consisting of providing a flatblank, forming the same into a tubular section having one end largerthan the other and of substantially oval cross section, bifurcating saidlarger end to divide it into a pair of channel-shaped arms, spreadingsaid arms apart to form a substantially Y-shaped member withsubstantially straight diverging arms, exerting bending pressure on saidarms adjacent their inner ends to form them into arcuate shape, anduniting a pair of such similar sections in longitudinal alignment.

3. The method of forming axle housings consisting of providing a flatblank having one end wider than the other and a tapered intermediateportion, forming said blank into a tubular section having its larger endsubstantially oval in section and its smaller end substantially circularin section, welding together the longitudinal edges of the blank,slotting said enlarged end from its free end to divide the enlarged endinto a pair of substantially channel arms, spreading and bending saidarms into arcuate contour and uniting a pair of such similar sections inlongitudinal alignment.

4. The method of making axle housings consisting of providing a flatblank having one end wider than the other and a tapered intermediateportion, said wider end having a pair of openings disposed upon oppositesides of its longitudinal center, forming said blank into a tubularsection having its larger end substantially oval in section and itssmaller end substantially circular in section, welding together thelongitudinal edges of the blank, slotting said enlarged end from itsfree end into said openings to divide the enlarged end into a pair ofchannel arms, spreading and bending said arms into arcuate contour, anduniting a pair of similar sections in longitudinal alignment.

5. The method of making axle housings consisting of providing a fiatblank having one end wider than the other and a tapered intermediateportion, said wider end having a pair of openings disposed upon oppositesides of its longitudinal center, forming said blank into a tubularsection having its larger end substantially oval in section and itssmaller end substantially circular in section, welding together thelongitudinal edges of the blanks, slotting said enlarged end from itsfree end into said opening to divide said end into a pair ofsubstantially channel-shaped arms, spreading said arms to substantiallyY-formation, forming said arms into arcuate shape to conjointly form asemi-circular enlarged forked end, and uniting the ends of the arms of apair of similar sections in longitudinal alignment.

6. The method of making axle housings, the steps which consist informing a blank with substantially rectangular ends, connected by atapered intermediate portion, one of said ends being substantially widerthan the other, forming said blank into tubular form with the wider endformed into substantially oval section, slotting said wider end atdiametrically opposite points to divide the same into a pair of arms,and spreading said arms apart and bending them into arcuate shape.

7. In a method of making axle housings, the steps which consist informing a blank with substantially rectangular ends of differentrelative size connected by a tapered intermediate portion,simultaneously providing said blank with a pair of spaced openings inthe larger end, forming said blank into tubular form with the wider endformed into substantially oval section with the openings diametricallydisposed, slitting said larger end from the openings out to the free endof the tube to divide the same into a pair of channel arms, andspreading said arms apart and bending them into arcuate shape.

8. The method of making axle housings consisting of blanking out a flatblank having one end wider than the other and an intermediate taperedportion, said wider end having a pair of spaced openings and thetransverse edge of said wider end having an extension, forming saidblank into tubular form with the longitudinal edges of the blanksubstantially contiguous, welding said edges together, one-half of thelarger end opposite the weld projecting beyond the other half, dividingsaid larger end in half to form a pair of arms, one of which is longerthan the other, spreading said arms apart and bending them into arcuateshape whereby the arms approximate each other in length, trimming theends of said arms, and uniting the arms of one section to the arms of asimilar section arranged in longitudinal alignment therewith.

9. A method of making axle housings consisting of providing a tubularsection having a 1ongitudinal welded seam and one end larger than theother, one half of the larger end being longer than the half possessingthe welded seam, dividing said larger end in half to form a pair of armsone of which is longer than the other, spreading said arms apart andbending them into arcuate shape whereby the arms approximate each otherin length, and uniting the arms 01. two similar sections arranged inlongitudinal alignment.

10. The method of forming axle housings consisting of providing atubular section having one end larger than the other and ofsubstantially oval cross section, bifurcating the larger end to divideit into a pair of substantially channelshaped arms, spreading said armsapart and bending them into arcuate shape, and uniting the ends of thearms of one section to the ends of the arms of a similar section inlongitudinal alignment by butt-welding.

11. The method of forming axle housings consisting of providing atubular section having one end larger than the other, with anintermediate tapered portion, said larger end being of substantiallyoval cross section, bifurcating the larger end from its free end to apoint adjacent the juncture of the tapered portion and larger end todivide it into a pair of substantially channel-shaped arms, the innerend of said bifurcation being arcuate to control the movement of themetal, spreading said arms apart and bending them to arcuate shape, anduniting the ends of the arms of one section to the ends of the arms of asimilar section in longitudinal alignment.

12. The method of forming axle housings consisting of providing atubular section having one end larger than the other, longitudinallyslotting said larger end to divide it into a pair of substantiallychannel-shaped arms, the longitudinal edges of the slots convergingtoward the free end of the tube whereby the channel-shaped armsgradually increase in depth toward their free ends, spreading the armsapart and bending them into arcuate shape thereby rendering the arms ofsubstantially uniform depth throughout their length and uniting the endsof the arms of one section to the ends of the arms of a similar sectionin longitudinal alignment.

13. A blank for the formation of an axle housing section comprising aflat body having one end of greater Width than the remainder of theblank, said wider end having a pair of spaced openings adjacent thelongitudinal edges thereof, and a longitudinally projecting extensionfrom its transverse edge, and said blank being adapted to be formedalong longitudinal lines into tubular shape to have its longitudinaledges welded together.

14. A blank for the formation of an axle housing section comprising aflat body and having one end of greater width than the remainder of theblank, the intermediate portion of the body having its longitudinaledges converging into the end of lesser width, said wider end having themiddle of its transverse edge provided with a longitudinally projectingextension and said blank being adapted to be formed along longitudinallines into tubular shape to have its longitudinal edges welded together.

15. A blank for the formation of axle housing sections comprising a fiatbody having one end of greater width than the remainder of the blank,said wider end having a pair of openings extending longitudinally of theblank toward the transverse edge of the wider end of the blank, and saidtransverse edge having a longitudinally projecting extension, said blankbeing adapted to be formed along longitudinal lines into tubular shapeto have its longitudinal edges welded together.

16. The method of forming a metallic article consisting of providing aflat blank, forming the same to tubular section having one endsubstantially oval section and larger than the other substantiallycircular end, bifurcating said larger end across its minor axis todivide it into a pair of channel-shaped arms, and spreading said armsapart.

17 A blank for the formation of an axle housing section comprising aflat blank having one end of greater width than the remainder of theblank, said wider end having a pair of spaced openings arranged to bediametrically aligned by the blank being bent along longitudinal linesto form the blank into tubular form for its longitudinal edges to bewelded together to provide a tubular structure.

18. A blank for the formation of an axle housing section comprising aflat blank having one end of greater width than the remainder of theblank, said wider end having a pair of spaced openings arranged to bediametrically aligned by the blank being bent along longitudinal linesto form the blank into tubular form for its longitudinal edges to bewelded together to provide a tubular structure, having its smaller endof substantially circular section and its larger end of substantiallyoval section.

19. An axle housing section formed from a fiat blank having one end ofgreater width than the remainder of the blank, said wider end having apair of spaced perforations spaced from the wider transverse edge of theblank and arranged to be diametricaly aligned by the blank being bentalong longitudinal lines to form it into tubular form for itslongitudinal edges to be welded together to thereby provide the largerend of the tubular form with demarcations for continuing theperforations to the wider transverse edge of the tubular form wherebythat wider end is provided with a pair of spaced substantiallychannel-shaped arms.

ERNEST RIEMENSCHNEIDER. WILLIAM BURT SMITH.

